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Provided herein is a roll laminate that can desirably reduce scrapes on a
metal foil surface even when a long metal foil is wound into a roll, and
that can improve the productivity in use of the unwound roll metal foil.
The roll laminate includes a long first metal foil and a long second
metal foil that are bonded to each other via an adhesive layer, and are
wound around a support. The adhesive layer has a thickness of 1 .mu.m or
more in at least a part of the layer, and is provided along the
longitudinal direction of the first and the second metal foil in at least
both edge portions in the width of an overlapping region of the first and
the second metal foil viewed in plan.

1. A roll laminate comprising a long first metal foil and a long second
metal foil that are bonded to each other via an adhesive layer, and are
wound around a support, wherein the adhesive layer has a thickness of 1
.mu.m or more in at least a part of the layer, and is provided along the
longitudinal direction of the first and the second metal foil in at least
both edge portions in the width of an overlapping region of the first and
the second metal foil viewed in plan, and wherein the roll laminate does
not fall into the following categories (A) to (C) of roll laminates: (A)
a roll laminate consisting of a structure in which: only a first
insulating layer and a first copper foil layer are provided in such order
that the roll laminate has the first insulating layer on the surface of
the first metal foil opposite the surface that is in contact with the
second metal foil, and the first copper foil layer on the surface of the
first insulating layer opposite the first metal foil, and only a second
insulating layer and a second copper foil layer are provided in such
order that the roll laminate has the second insulating layer on the
surface of the second metal foil opposite the surface that is in contact
with the first metal foil, and the second copper foil layer on the
surface of the second insulating layer opposite the surface that is in
contact with the second metal foil; (B) a roll laminate consisting of a
structure in which: only a first insulating layer, a first copper foil
layer, and a via hole are provided, wherein the first insulating layer is
provided on the surface of the first metal foil opposite the surface that
is in contact with the second metal foil, the first copper foil layer is
provided on the surface of the first insulating layer opposite the
surface that is in contact with the first metal foil, and the via hole is
provided through the first insulating layer and the first copper foil
layer, and only a second insulating layer, a second copper foil layer,
and a via hole are provided, wherein the second insulating layer is
provided on the surface of the second metal foil opposite the surface
that is in contact with the first metal foil, the second copper foil
layer is provided on the surface of the second insulating layer opposite
the surface that is in contact with the second metal foil, and the via
hole is provided through the second insulating layer and the second
copper foil layer; and (C) a roll laminate consisting of a structure in
which: only a first insulating layer, a first copper foil layer, a first
metal layer, and a first via hole are provided, wherein the first
insulating layer is provided on the surface of the first metal foil
opposite the surface that is in contact with the second metal foil, the
first copper foil layer is provided on the surface of the first
insulating layer opposite the surface that is in contact with the first
metal foil, the first via hole is provided through the first insulating
layer and the first copper foil layer, and the first metal layer is
provided on the surface of the first copper foil layer opposite the
surface that is in contact with the first insulating layer, and in the
first via hole, and only a second insulating layer, a second copper foil
layer, a second metal layer, and a second via hole are provided, wherein
the second insulating layer is provided on the surface of the second
metal foil opposite the surface that is in contact with the first metal
foil, the second copper foil layer is provided on the surface of the
second insulating layer opposite the surface that is in contact with the
second metal foil, the second via hole is provided through the second
insulating layer and the second copper foil layer, and the second metal
layer is provided on the surface of the second copper foil layer opposite
the surface that is in contact with the second insulating layer, and in
the second via hole.

2. The roll laminate according to claim 1, wherein the adhesive layer has
a thickness of 300 .mu.m or less.

3. The roll laminate according to claim 1, wherein the adhesive layer has
a width of 0.5 mm or more.

4. The roll laminate according to claim 1, wherein the adhesive layer has
a width of 100 mm or less.

5. The roll laminate according to claim 1, wherein the first metal foil
and the second metal foil each have a thickness of 5 to 70 .mu.m.

6. The roll laminate according to claim 1, wherein the adhesive layer is
provided either continuously or discontinuously along the longitudinal
direction of the first and the second metal foil.

7. A roll laminate comprising a long first metal foil and a long second
metal foil that are bonded to each other via an adhesive layer, and are
wound around a support, wherein the adhesive layer has a thickness of 1
.mu.m or more in at least a part of the layer, and is provided along the
longitudinal direction of the first and the second metal foil in at least
both edge portions in the width of an overlapping region of the first and
the second metal foil viewed in plan, and wherein the roll laminate
satisfies the formula 0.ltoreq.d.ltoreq.0.1.times.r, where d is the
maximum depth of a gap created between the outermost surface of the roll
laminate in the thickness direction of the first and the second metal
foil, and a straight line drawn to connect the apices of bumps present on
the outermost surface of the roll laminate in positions corresponding to
the adhesive layers at both edge portions in the width of the first and
the second metal foil, and r is the roll thickness of the roll laminate.

8. The roll laminate according to claim 7, which satisfies at least one
of the following (1) to (5): (1) the adhesive layer has a thickness of
300 .mu.m or less; (2) the adhesive layer has a width of 0.5 mm or more;
(3) the adhesive layer has a width of 100 mm or less; (4) the first metal
foil and the second metal foil each have a thickness of 5 to 70 .mu.m;
and (5) the adhesive layer is provided either continuously or
discontinuously along the longitudinal direction of the first and the
second metal foil.

9. The roll laminate according to claim 7, wherein the maximum depth (d)
of the gap created between the straight line and the outermost surface of
the roll laminate, and the roll thickness (r) of the roll laminate
satisfy the formula 0.ltoreq.d.ltoreq.0.05.times.r.

10. The roll laminate according to claim 1, wherein the adhesive
constituting the adhesive layer has a viscosity of 3.times.10.sup.6 mPas
(25.degree. C.) or less after 3 minutes from application.

11. The roll laminate according to claim 10, wherein the adhesive
constituting the adhesive layer has a viscosity of 1.times.10.sup.6 mPas
(25.degree. C.) or less after 3 minutes from application.

12. A roll laminate comprising a long first metal foil and a long second
metal foil that are bonded to each other via an adhesive layer, and are
wound around a support, wherein the adhesive layer has a thickness of 1
.mu.m or more in at least a part of the layer, and is provided along the
longitudinal direction of the first and the second metal foil in at least
both edge portions in the width of an overlapping region of the first and
the second metal foil viewed in plan, and wherein: (a) one of the first
metal foil and the second metal foil protrudes beyond the other metal
foil at the both ends in the width of the roll laminate in a plan view of
the first and the second metal foil; (b) one of the first metal foil and
the second metal foil protrudes beyond the other metal foil at one end of
the roll laminate in the width direction, and the other metal foil
protrudes beyond one of the first metal foil and the second foil at the
other end of the roll laminate in the width direction in a plan view of
the first and the second metal foil; or (c) one of the first metal foil
and the second metal foil protrudes beyond the other metal foil at one
end of the roll laminate in the width direction, and the first and the
second metal foil have aligned end portions at the other end of the roll
laminate in the width direction in a plan view of the first and the
second metal foil.

13. The roll laminate according to claim 12, which satisfies at least one
of the following (1) to (9): (1) the adhesive layer has a thickness of
300 .mu.m or less; (2) the adhesive layer has a width of 0.5 mm or more;
(3) the adhesive layer has a width of 100 mm or less; (4) the first metal
foil and the second metal foil each have a thickness of 5 to 70 .mu.m;
(5) the adhesive layer is provided either continuously or discontinuously
along the longitudinal direction of the first and the second metal foil;
(6) the roll laminate satisfies the formula
0.ltoreq.d.ltoreq.0.1.times.r, where d is the maximum depth of a gap
created between the outermost surface of the roll laminate in the
thickness direction of the first and the second metal foil, and a
straight line drawn to connect the apices of bumps present on the
outermost surface of the roll laminate in positions corresponding to the
adhesive layers at both edge portions in the width of the first and the
second metal foil, and r is the roll thickness of the roll laminate; (7)
the maximum depth (d) of the gap created between the straight line and
the outermost surface of the roll laminate, and the roll thickness (r) of
the roll laminate as defined in (6) satisfy the formula
0.ltoreq.d.ltoreq.0.05.times.r; (8) the adhesive constituting the
adhesive layer has a viscosity of 3.times.10.sup.6 mPas (25.degree. C.)
or less after 3 minutes from application; and (9) the adhesive
constituting the adhesive layer has a viscosity of 1.times.10.sup.6 mPas
(25.degree. C.) or less after 3 minutes from application.

14. A roll laminate comprising a long first metal foil and a long second
metal foil that are bonded to each other via an adhesive layer, and are
wound around a support, wherein the adhesive layer has a thickness of 1
.mu.m or more in at least a part of the layer, and is provided along the
longitudinal direction of the first and the second metal foil in at least
both edge portions in the width of an overlapping region of the first and
the second metal foil viewed in plan, and wherein: the first metal foil
is a carrier for a carrier-attached metal foil that includes the carrier,
an interlayer, and an ultrathin metal layer, in this order, and the
second metal foil is the ultrathin metal layer for another
carrier-attached metal foil that includes a carrier, an interlayer, and
an ultrathin metal layer, in this order.

15. A roll laminate comprising a long first metal foil and a long second
metal foil that are bonded to each other via an adhesive layer, and are
wound around a support, wherein the adhesive layer has a thickness of 1
.mu.m or more in at least a part of the layer, and is provided along the
longitudinal direction of the first and the second metal foil in at least
both edge portions in the width of an overlapping region of the first and
the second metal foil viewed in plan, and wherein the first metal foil
and the second metal foil each comprise a carrier-attached metal foil
that includes a carrier, an interlayer, and an ultrathin metal layer, in
this order.

16. The roll laminate according to claim 15, which satisfies at least one
of the following (1) to (10): (1) the adhesive layer has a thickness of
300 .mu.m or less; (2) the adhesive layer has a width of 0.5 mm or more;
(3) the adhesive layer has a width of 100 mm or less; (4) the first metal
foil and the second metal foil each have a thickness of 5 to 70 .mu.m;
(5) the adhesive layer is provided either continuously or discontinuously
along the longitudinal direction of the first and the second metal foil;
(6) the roll laminate satisfies the formula
0.ltoreq.d.ltoreq.0.1.times.r, where d is the maximum depth of a gap
created between the outermost surface of the roll laminate in the
thickness direction of the first and the second metal foil, and a
straight line drawn to connect the apices of bumps present on the
outermost surface of the roll laminate in positions corresponding to the
adhesive layers at both edge portions in the width of the first and the
second metal foil, and r is the roll thickness of the roll laminate; (7)
the maximum depth (d) of the gap created between the straight line and
the outermost surface of the roll laminate, and the roll thickness (r) of
the roll laminate as defined in (6) satisfy the formula
0.ltoreq.d.ltoreq.0.05.times.r; (8) the adhesive constituting the
adhesive layer has a viscosity of 3.times.10.sup.6 mPas (25.degree. C.)
or less after 3 minutes from application; (9) the adhesive constituting
the adhesive layer has a viscosity of 1.times.10.sup.6 mPas (25.degree.
C.) or less after 3 minutes from application; and (10) (a) the first
metal foil or the second metal foil protrudes beyond the other at the
both ends in the width of the roll laminate in a plan view of the first
and the second metal foil, (b) the first metal foil or the second metal
foil protrudes beyond the other at one end of the roll laminate in the
width direction, and the other metal foil protrudes beyond the other at
the other end of the roll laminate in the width direction in a plan view
of the first and the second metal foil, or (c) the first metal foil or
the second metal foil protrudes beyond the other at one end of the roll
laminate in the width direction, and the first and the second metal foil
have aligned end portions at the other end of the roll laminate in the
width direction in a plan view of the first and the second metal foil.

17. A method for producing a roll laminate, the method comprising:
providing an adhesive layer along the longitudinal direction of a long
first metal foil at both edge portions in the width of the first metal
foil, wherein the first metal foil is not a metal foil that includes
solely an insulating layer and a copper foil in this order on the surface
opposite the surface provided with the adhesive layer; bonding a long
second metal foil to the adhesive layer-side surface of the first metal
foil provided with the adhesive layer, wherein the second metal foil is
not a metal foil that includes solely an insulating layer and a copper
foil in this order on the surface opposite the surface bonded to the
first metal foil; and winding around a support the long first metal foil
and the long second metal foil that are bonded to each other via the
adhesive layer.

18. A method for producing a roll laminate, the method comprising: taking
the first and the second metal foil from (i) a roll laminate comprising a
long first metal foil and a long second metal foil that are bonded to
each other via an adhesive layer, and are wound around a support, wherein
the adhesive layer has a thickness of 1 .mu.m or more in at least a part
of the layer, and is provided along the longitudinal direction of the
first and the second metal foil in at least both edge portions in the
width of an overlapping region of the first and the second metal foil
viewed in plan, or (ii) a roll laminate produced by the method of claim
17; laminating a resin on at least one of the first metal foil and the
second metal foil; and winding the first metal foil, the second metal
foil, and the resin around a support.

19. The method according to claim 18, wherein the roll laminate satisfies
at least one of the following (1) to (12): (1) the adhesive layer has a
thickness of 300 .mu.m or less; (2) the adhesive layer has a width of 0.5
mm or more; (3) the adhesive layer has a width of 100 mm or less; (4) the
first metal foil and the second metal foil each have a thickness of 5 to
70 .mu.m; (5) the adhesive layer is provided either continuously or
discontinuously along the longitudinal direction of the first and the
second metal foil; (6) the roll laminate satisfies the formula
0.ltoreq.d.ltoreq.0.1.times.r, where d is the maximum depth of a gap
created between the outermost surface of the roll laminate in the
thickness direction of the first and the second metal foil, and a
straight line drawn to connect the apices of bumps present on the
outermost surface of the roll laminate in positions corresponding to the
adhesive layers at both edge portions in the width of the first and the
second metal foil, and r is the roll thickness of the roll laminate; (7)
the maximum depth (d) of the gap created between the straight line and
the outermost surface of the roll laminate, and the roll thickness (r) of
the roll laminate as defined in (6) satisfy the formula
0.ltoreq.d.ltoreq.0.05.times.r; (8) the adhesive constituting the
adhesive layer has a viscosity of 3.times.10.sup.6 mPas (25.degree. C.)
or less after 3 minutes from application; (9) the adhesive constituting
the adhesive layer has a viscosity of 1.times.10.sup.6 mPas (25.degree.
C.) or less after 3 minutes from application; (10) (a) the first metal
foil or the second metal foil protrudes beyond the other at the both ends
in the width of the roll laminate in a plan view of the first and the
second metal foil, (b) the first metal foil or the second metal foil
protrudes beyond the other at one end of the roll laminate in the width
direction, and the other metal foil protrudes beyond the other at the
other end of the roll laminate in the width direction in a plan view of
the first and the second metal foil, or (c) the first metal foil or the
second metal foil protrudes beyond the other at one end of the roll
laminate in the width direction, and the first and the second metal foil
have aligned end portions at the other end of the roll laminate in the
width direction in a plan view of the first and the second metal foil;
(11) the first metal foil is a carrier for a carrier-attached metal foil
that includes a carrier, an interlayer, and an ultrathin metal layer, in
this order, and the second metal foil is the ultrathin metal layer; and
(12) the first metal foil and the second metal foil each comprise a
carrier-attached metal foil that includes a carrier, an interlayer, and
an ultrathin metal layer, in this order.

20. A method for producing a laminate, the method comprising taking the
first and the second metal foil from the roll laminate of claim 1 to
produce a laminate that includes the first and the second metal foil.

21. A method for producing a laminate, the method comprising taking the
first and the second metal foil from the roll laminate of claim 7 to
produce a laminate that includes the first and the second metal foil.

22. A method for producing a laminate, the method comprising taking the
first and the second metal foil from the roll laminate of claim 12 to
produce a laminate that includes the first and the second metal foil.

23. A method for producing a laminate, the method comprising taking the
first and the second metal foil from the roll laminate of claim 15 to
produce a laminate that includes the first and the second metal foil.

24. A method for producing a laminate, the method comprising taking the
first and the second metal foil from a roll laminate produced by the
method of claim 17 to produce a laminate that includes the first and the
second metal foil.

25. A method for producing a laminate, the method comprising taking the
first and the second metal foil from a roll laminate produced by the
method of claim 18 to produce a laminate that includes the first and the
second metal foil.

26. A method for producing a build-up substrate, the method comprising:
forming one or more build-up wiring layers on at least one surface of a
laminate produced by a method for producing a laminate that includes a
first and a second metal foil by taking the first and the second metal
foil from (i) a roll laminate comprising a long first metal foil and a
long second metal foil that are bonded to each other via an adhesive
layer, and are wound around a support, wherein the adhesive layer has a
thickness of 1 .mu.m or more in at least a part of the layer, and is
provided along the longitudinal direction of the first and the second
metal foil in at least both edge portions in the width of an overlapping
region of the first and the second metal foil viewed in plan, or (ii) a
roll laminate produced by the method of claim 17.

27. The method according to claim 26, wherein the roll laminate satisfies
at least one of the following (1) to (12): (1) the adhesive layer has a
thickness of 300 .mu.m or less; (2) the adhesive layer has a width of 0.5
mm or more; (3) the adhesive layer has a width of 100 mm or less; (4) the
first metal foil and the second metal foil each have a thickness of 5 to
70 .mu.m; (5) the adhesive layer is provided either continuously or
discontinuously along the longitudinal direction of the first and the
second metal foil; (6) the roll laminate satisfies the formula
0.ltoreq.d.ltoreq.0.1.times.r, where d is the maximum depth of a gap
created between the outermost surface of the roll laminate in the
thickness direction of the first and the second metal foil, and a
straight line drawn to connect the apices of bumps present on the
outermost surface of the roll laminate in positions corresponding to the
adhesive layers at both edge portions in the width of the first and the
second metal foil, and r is the roll thickness of the roll laminate; (7)
the maximum depth (d) of the gap created between the straight line and
the outermost surface of the roll laminate, and the roll thickness (r) of
the roll laminate as defined in (6) satisfy the formula
0.ltoreq.d.ltoreq.0.05.times.r; (8) the adhesive constituting the
adhesive layer has a viscosity of 3.times.10.sup.6 mPas (25.degree. C.)
or less after 3 minutes from application; (9) the adhesive constituting
the adhesive layer has a viscosity of 1.times.10.sup.6 mPas (25.degree.
C.) or less after 3 minutes from application; (10) (a) the first metal
foil or the second metal foil protrudes beyond the other at the both ends
in the width of the roll laminate in a plan view of the first and the
second metal foil, (b) the first metal foil or the second metal foil
protrudes beyond the other at one end of the roll laminate in the width
direction, and the other metal foil protrudes beyond the other at the
other end of the roll laminate in the width direction in a plan view of
the first and the second metal foil, or (c) the first metal foil or the
second metal foil protrudes beyond the other at one end of the roll
laminate in the width direction, and the first and the second metal foil
have aligned end portions at the other end of the roll laminate in the
width direction in a plan view of the first and the second metal foil;
(11) the first metal foil is a carrier for a carrier-attached metal foil
that includes a carrier, an interlayer, and an ultrathin metal layer, in
this order, and the second metal foil is the ultrathin metal layer; and
(12) the first metal foil and the second metal foil each comprise a
carrier-attached metal foil that includes a carrier, an interlayer, and
an ultrathin metal layer, in this order.

28. The method according to claim 26, wherein the build-up wiring layers
are formed by using at least one of a subtractive method, a full-additive
method, and a semi-additive method.

29. A method for producing a build-up substrate, the method comprising:
laminating at least once a resin, a one-sided or double-sided wiring
board, a one-sided or double-sided metal clad laminate, a laminate A, a
resin substrate-attached metal layer, a carrier-attached metal layer, a
wire, a circuit, or a metal layer on at least one surface of a laminate A
produced by a method for producing a laminate A that includes a first and
a second metal foil by taking the first and the second metal foil from
(i) a roll laminate comprising a long first metal foil and a long second
metal foil that are bonded to each other via an adhesive layer, and are
wound around a support, wherein the adhesive layer has a thickness of 1
.mu.m or more in at least a part of the layer, and is provided along the
longitudinal direction of the first and the second metal foil in at least
both edge portions in the width of an overlapping region of the first and
the second metal foil viewed in plan, or (ii) a roll laminate produced by
the method of claim 17.

30. The method according to claim 29, wherein the roll laminate satisfies
at least one of the following (1) to (12): (1) the adhesive layer has a
thickness of 300 .mu.m or less; (2) the adhesive layer has a width of 0.5
mm or more; (3) the adhesive layer has a width of 100 mm or less; (4) the
first metal foil and the second metal foil each have a thickness of 5 to
70 .mu.m; (5) the adhesive layer is provided either continuously or
discontinuously along the longitudinal direction of the first and the
second metal foil; (6) the roll laminate satisfies the formula
0.ltoreq.d.ltoreq.0.1.times.r, where d is the maximum depth of a gap
created between the outermost surface of the roll laminate in the
thickness direction of the first and the second metal foil, and a
straight line drawn to connect the apices of bumps present on the
outermost surface of the roll laminate in positions corresponding to the
adhesive layers at both edge portions in the width of the first and the
second metal foil, and r is the roll thickness of the roll laminate; (7)
the maximum depth (d) of the gap created between the straight line and
the outermost surface of the roll laminate, and the roll thickness (r) of
the roll laminate as defined in (6) satisfy the formula
0.ltoreq.d.ltoreq.0.05.times.r; (8) the adhesive constituting the
adhesive layer has a viscosity of 3.times.10.sup.6 mPas (25.degree. C.)
or less after 3 minutes from application; (9) the adhesive constituting
the adhesive layer has a viscosity of 1.times.10.sup.6 mPas (25.degree.
C.) or less after 3 minutes from application; (10) (a) the first metal
foil or the second metal foil protrudes beyond the other at the both ends
in the width of the roll laminate in a plan view of the first and the
second metal foil, (b) the first metal foil or the second metal foil
protrudes beyond the other at one end of the roll laminate in the width
direction, and the other metal foil protrudes beyond the other at the
other end of the roll laminate in the width direction in a plan view of
the first and the second metal foil, or (c) the first metal foil or the
second metal foil protrudes beyond the other at one end of the roll
laminate in the width direction, and the first and the second metal foil
have aligned end portions at the other end of the roll laminate in the
width direction in a plan view of the first and the second metal foil;
(11) the first metal foil is a carrier for a carrier-attached metal foil
that includes a carrier, an interlayer, and an ultrathin metal layer, in
this order, and the second metal foil is the ultrathin metal layer; and
(12) the first metal foil and the second metal foil each comprise a
carrier-attached metal foil that includes a carrier, an interlayer, and
an ultrathin metal layer, in this order.

31. The method according to claim 29, further comprising: boring the
resin, the one-sided or double-sided circuit board, the one-sided or
double-sided metal clad laminate, the laminate A, the resin
substrate-attached metal layer, the carrier-attached metal layer, the
wire, the circuit, or the metal layer; and subjecting a side surface and
a bottom surface of the bore to conductive plating.

32. The method according to claim 29, further comprising: forming a wire
at least once on at least one of a metal layer constituting the one-sided
or double-sided circuit board, a metal layer constituting the one-sided
or double-sided metal clad laminate, a metal foil constituting the
laminate A, a metal layer constituting the carrier-attached metal layer,
a metal layer constituting the resin substrate-attached metal layer, and
the metal layer.

33. The method according to claim 29, further comprising: laminating, on
a wired surface, a laminate produced by a method for producing a laminate
that includes the first and the second metal foil by taking the first and
the second metal foil from a roll laminate comprising a long first metal
foil and a long second metal foil that are bonded to each other via an
adhesive layer, and are wound around a support, wherein the adhesive
layer has a thickness of 1 .mu.m or more in at least a part of the layer,
and is provided along the longitudinal direction of the first and the
second metal foil in at least both edge portions in the width of an
overlapping region of the first and the second metal foil viewed in plan.

34. The method according to claim 33, wherein the roll laminate satisfies
at least one of the following (1) to (12): (1) the adhesive layer has a
thickness of 300 .mu.m or less; (2) the adhesive layer has a width of 0.5
mm or more; (3) the adhesive layer has a width of 100 mm or less; (4) the
first metal foil and the second metal foil each have a thickness of 5 to
70 .mu.m; (5) the adhesive layer is provided either continuously or
discontinuously along the longitudinal direction of the first and the
second metal foil; (6) the roll laminate satisfies the formula
0.ltoreq.d.ltoreq.0.1.times.r, where d is the maximum depth of a gap
created between the outermost surface of the roll laminate in the
thickness direction of the first and the second metal foil, and a
straight line drawn to connect the apices of bumps present on the
outermost surface of the roll laminate in positions corresponding to the
adhesive layers at both edge portions in the width of the first and the
second metal foil, and r is the roll thickness of the roll laminate; (7)
the maximum depth (d) of the gap created between the straight line and
the outermost surface of the roll laminate, and the roll thickness (r) of
the roll laminate as defined in (6) satisfy the formula
0.ltoreq.d.ltoreq.0.05.times.r; (8) the adhesive constituting the
adhesive layer has a viscosity of 3.times.10.sup.6 mPas (25.degree. C.)
or less after 3 minutes from application; (9) the adhesive constituting
the adhesive layer has a viscosity of 1.times.10.sup.6 mPas (25.degree.
C.) or less after 3 minutes from application; (10) (a) the first metal
foil or the second metal foil protrudes beyond the other at the both ends
in the width of the roll laminate in a plan view of the first and the
second metal foil, (b) the first metal foil or the second metal foil
protrudes beyond the other at one end of the roll laminate in the width
direction, and the other metal foil protrudes beyond the other at the
other end of the roll laminate in the width direction in a plan view of
the first and the second metal foil, or (c) the first metal foil or the
second metal foil protrudes beyond the other at one end of the roll
laminate in the width direction, and the first and the second metal foil
have aligned end portions at the other end of the roll laminate in the
width direction in a plan view of the first and the second metal foil;
(11) the first metal foil is a carrier for a carrier-attached metal foil
that includes a carrier, an interlayer, and an ultrathin metal layer, in
this order, and the second metal foil is the ultrathin metal layer; and
(12) the first metal foil and the second metal foil each comprise a
carrier-attached metal foil that includes a carrier, an interlayer, and
an ultrathin metal layer, in this order.

35. The method according to claim 29, comprising: cutting the laminate A
at at least one laminated surface of the metal foils viewed in plan.

36. The method according to claim 35, further comprising: detaching and
separating the metal foils of the cut laminate from each other.

37. The method according to claim 36, further comprising: removing the
detached and separated metal foil either in part or as a whole by
etching.

38. A method for producing a printed wiring board, wherein the method
uses a laminate produced by a method for producing a laminate that
includes the first and the second metal foil by taking the first and the
second metal foil from a roll laminate produced by the method of claim
17.

39. A method for producing a printed wiring board using a build-up
substrate produced by the method of claim 26.

40. The method according to claim 38, wherein the roll laminate satisfies
at least one of the following (1) to (12): (1) the adhesive layer has a
thickness of 300 .mu.m or less; (2) the adhesive layer has a width of 0.5
mm or more; (3) the adhesive layer has a width of 100 mm or less; (4) the
first metal foil and the second metal foil each have a thickness of 5 to
70 .mu.m; (5) the adhesive layer is provided either continuously or
discontinuously along the longitudinal direction of the first and the
second metal foil; (6) the roll laminate satisfies the formula
0.ltoreq.d.ltoreq.0.1.times.r, where d is the maximum depth of a gap
created between the outermost surface of the roll laminate in the
thickness direction of the first and the second metal foil, and a
straight line drawn to connect the apices of bumps present on the
outermost surface of the roll laminate in positions corresponding to the
adhesive layers at both edge portions in the width of the first and the
second metal foil, and r is the roll thickness of the roll laminate; (7)
the maximum depth (d) of the gap created between the straight line and
the outermost surface of the roll laminate, and the roll thickness (r) of
the roll laminate as defined in (6) satisfy the formula
0.ltoreq.d.ltoreq.0.05.times.r; (8) the adhesive constituting the
adhesive layer has a viscosity of 3.times.10.sup.6 mPas (25.degree. C.)
or less after 3 minutes from application; (9) the adhesive constituting
the adhesive layer has a viscosity of 1.times.10.sup.6 mPas (25.degree.
C.) or less after 3 minutes from application; (10) (a) the first metal
foil or the second metal foil protrudes beyond the other at the both ends
in the width of the roll laminate in a plan view of the first and the
second metal foil, (b) the first metal foil or the second metal foil
protrudes beyond the other at one end of the roll laminate in the width
direction, and the other metal foil protrudes beyond the other at the
other end of the roll laminate in the width direction in a plan view of
the first and the second metal foil, or (c) the first metal foil or the
second metal foil protrudes beyond the other at one end of the roll
laminate in the width direction, and the first and the second metal foil
have aligned end portions at the other end of the roll laminate in the
width direction in a plan view of the first and the second metal foil;
(11) the first metal foil is a carrier for a carrier-attached metal foil
that includes a carrier, an interlayer, and an ultrathin metal layer, in
this order, and the second metal foil is the ultrathin metal layer; and
(12) the first metal foil and the second metal foil each comprise a
carrier-attached metal foil that includes a carrier, an interlayer, and
an ultrathin metal layer, in this order.

41. A method for producing an electronic device using a printed wiring
board produced by the method of claim 38.

42. A method for producing an electronic device using a printed wiring
board produced by the method of claim 39.

Description

TECHNICAL FIELD

[0001] The present invention relates to a roll laminate, a method for
producing a roll laminate, a method for producing a laminate, a method
for producing a build-up substrate, a method for producing a printed
wiring board, and a method for producing an electronic device.

[0002] A printed wiring board is typically formed through the process of
bonding an insulating substrate to a copper foil to produce a copper-clad
laminate, and etching a copper foil surface to form a conductor pattern.
Metal foils such as a copper foil are used for the production of a
printed wiring board.

[0003] In a traditional method of metal foil production, a metal foil is
often rolled by being wound around a support. Here, the winding of the
metal foil often involves meandering. Winding a meandering metal foil
into a coil causes a misalignment on a wind-up reel. Such a misalignment
causes metal foil layers to rub against each other, and scrapes the metal
foil surface.

[0004] This problem is addressed in JP-A-2009-22998, which discloses a
metal foil winder for successively winding a rolled metal foil into a
coil around a wind-up reel. The winder includes an interleaving paper
unwinding roll for unwinding the interleaving paper that becomes inserted
between layers of the coiled metal foil. The interleaving paper roll is
wider than the metal foil. With this configuration, JP-A-2009-22998 is
intended to prevent scrapes on a metal foil even when a misalignment
occurs as a result of meandering of the metal foil when successively
winding a rolled metal foil into a coil around a wind-up reel, and
improve the quality of the end product metal foil.

CITATION LIST

Patent Literature

[0005] PTL 1: JP-A-2009-22998

SUMMARY OF INVENTION

Technical Problem

[0006] However, the technique described in JP-A-2009-22998 involves the
process of removing the interleaving paper when processing a roll of
metal foil by unwinding it into a metal foil sheet. This is problematic
in terms of production efficiency.

[0007] It is accordingly an object of the present invention to provide a
roll laminate that can desirably reduce scrapes on a metal foil surface
even when a long metal foil is wound into a roll, and that can improve
the productivity in use of the unwound roll metal foil.

Solution to Problem

[0008] The present inventors diligently worked to achieve the foregoing
object, and found that scrapes on a metal foil surface can be desirably
reduced even when a long metal foil is wound into a roll, and the
productivity in use of the unwound roll metal foil can improve when long
metal foils are bonded to each other with an adhesive layer of a
predetermined thickness provided at predetermined locations, and are
wound around a support to form a roll laminate.

[0009] The present invention was completed on the basis of this finding,
and an aspect of the invention is a roll laminate comprising a long first
metal foil and along second metal foil that are bonded to each other via
an adhesive layer, and are wound around a support. The adhesive layer has
a thickness of 1 .mu.m or more in at least a part of the layer, and is
provided along the longitudinal direction of the first and the second
metal foil in at least both edge portions in the width of an overlapping
region of the first and the second metal foil viewed in plan.

[0010] An embodiment of the roll laminate of the present invention is a
roll laminate,

[0011] wherein the roll laminate does not fall into the following
categories (A) to (C) of roll laminate:

[0012] (A) a roll laminate consisting of a structure in which:

[0013] only a first insulating layer and a first copper foil layer are
provided in such order that the roll laminate has the first insulating
layer on the surface of the first metal foil opposite the surface that is
in contact with the second metal foil, and the first copper foil layer on
the surface of the first insulating layer opposite the first metal foil,
and

[0014] only a second insulating layer and a second copper foil layer are
provided in such order that the roll laminate has the second insulating
layer on the surface of the second metal foil opposite the surface that
is in contact with the first metal foil, and the second copper foil layer
on the surface of the second insulating layer opposite the surface that
is in contact with the second metal foil;

[0015] (B) a roll laminate consisting of a structure in which:

[0016] only a first insulating layer, a first copper foil layer, and a via
hole are provided, wherein the first insulating layer is provided on the
surface of the first metal foil opposite the surface that is in contact
with the second metal foil, the first copper foil layer is provided on
the surface of the first insulating layer opposite the surface that is in
contact with the first metal foil, and the via hole is provided through
the first insulating layer and the first copper foil layer, and

[0017] only a second insulating layer, a second copper foil layer, and a
via hole are provided, wherein the second insulating layer is provided on
the surface of the second metal foil opposite the surface that is in
contact with the first metal foil, the second copper foil layer is
provided on the surface of the second insulating layer opposite the
surface that is in contact with the second metal foil, and the via hole
is provided through the second insulating layer and the second copper
foil layer; and

[0018] (C) a roll laminate consisting of a structure in which:

[0019] only a first insulating layer, a first copper foil layer, a first
metal layer, and a first via hole are provided, wherein the first
insulating layer is provided on the surface of the first metal foil
opposite the surface that is in contact with the second metal foil, the
first copper foil layer is provided on the surface of the first
insulating layer opposite the surface that is in contact with the first
metal foil, the first via hole is provided through the first insulating
layer and the first copper foil layer, and the first metal layer is
provided on the surface of the first copper foil layer opposite the
surface that is in contact with the first insulating layer, and in the
first via hole, and

[0020] only a second insulating layer, a second copper foil layer, a
second metal layer, and a second via hole are provided, wherein the
second insulating layer is provided on the surface of the second metal
foil opposite the surface that is in contact with the first metal foil,
the second copper foil layer is provided on the surface of the second
insulating layer opposite the surface that is in contact with the second
metal foil, the second via hole is provided through the second insulating
layer and the second copper foil layer, and the second metal layer is
provided on the surface of the second copper foil layer opposite the
surface that is in contact with the second insulating layer, and in the
second via hole.

[0021] In an embodiment of the roll laminate of the present invention, the
adhesive layer has a thickness of 300 .mu.m or less.

[0022] In another embodiment of the roll laminate of the present
invention, the adhesive layer has a width of 0.5 mm or more.

[0023] In yet another embodiment of the roll laminate of the present
invention, the adhesive layer has a width of 100 mm or less.

[0024] In still another embodiment of the roll laminate of the present
invention, the first metal foil and the second metal foil each have a
thickness of 5 to 70 .mu.m.

[0025] In yet another embodiment of the roll laminate of the present
invention, the adhesive layer is provided either continuously or
discontinuously along the longitudinal direction of the first and the
second metal foil.

[0026] Another aspect of the present invention is a roll laminate
comprising a long first metal foil and a long second metal foil that are
bonded to each other via an adhesive layer, and are wound around a
support,

[0027] wherein the adhesive layer has a thickness of 1 .mu.m or more in at
least a part of the layer, and is provided along the longitudinal
direction of the first and the second metal foil in at least both edge
portions in the width of an overlapping region of the first and the
second metal foil viewed in plan, and

[0028] wherein the roll laminate satisfies the formula
0.ltoreq.d.ltoreq.0.1.times.r, where d is the maximum depth of a gap
created between the outermost surface of the roll laminate in the
thickness direction of the first and the second metal foil, and a
straight line drawn to connect the apices of bumps present on the
outermost surface of the roll laminate in positions corresponding to the
adhesive layers at both edge portions in the width of the first and the
second metal foil, and r is the roll thickness of the roll laminate.

[0029] In another embodiment of the roll laminate of the present
invention, the roll laminate satisfies at least one of the following (1)
to (5):

[0030] (1) the adhesive layer has a thickness of 300 .mu.m or less;

[0031] (2) the adhesive layer has a width of 0.5 mm or more;

[0032] (3) the adhesive layer has a width of 100 mm or less;

[0033] (4) the first metal foil and the second metal foil each have a
thickness of 5 to 70 .mu.m; and

[0034] (5) the adhesive layer is provided either continuously or
discontinuously along the longitudinal direction of the first and the
second metal foil.

[0035] In yet another embodiment of the roll laminate of the present
invention, the maximum depth (d) of the gap created between the straight
line and the outermost surface of the roll laminate, and the roll
thickness (r) of the roll laminate satisfy the formula
0.ltoreq.d.ltoreq.0.05.times.r.

[0036] In still another embodiment of the roll laminate of the present
invention, the adhesive constituting the adhesive layer has a viscosity
of 3.times.10.sup.6 mPas (25.degree. C.) or less after 3 minutes from
application.

[0037] In yet another embodiment of the roll laminate of the present
invention, the adhesive constituting the adhesive layer has a viscosity
of 1.times.10.sup.6 mPas (25.degree. C.) or less after 3 minutes from
application.

[0038] Still another aspect of the present invention is a roll laminate
comprising a long first metal foil and a long second metal foil that are
bonded to each other via an adhesive layer, and are wound around a
support,

[0039] wherein the adhesive layer has a thickness of 1 .mu.m or more in at
least a part of the layer, and is provided along the longitudinal
direction of the first and the second metal foil in at least both edge
portions in the width of an overlapping region of the first and the
second metal foil viewed in plan, and

[0040] wherein:

[0041] (a) the first metal foil or the second metal foil protrudes beyond
the other at the both ends in the width of the roll laminate in a plan
view of the first and the second metal foil;

[0042] (b) one of the first metal foil and the second metal foil protrudes
beyond the other metal foil at one end of the roll laminate in the width
direction, and the other metal foil protrudes beyond the other at the
other end of the roll laminate in the width direction in a plan view of
the first and the second metal foil; or

[0043] (c) one of the first metal foil and the second metal foil protrudes
beyond the other metal foil at one end of the roll laminate in the width
direction, and the first and the second metal foil have aligned end
portions at the other end of the roll laminate in the width direction in
a plan view of the first and the second metal foil.

[0044] In another embodiment of the roll laminate of the present
invention, the roll laminate satisfies at least one of the following (1)
to (9):

[0045] (1) the adhesive layer has a thickness of 300 .mu.m or less;

[0046] (2) the adhesive layer has a width of 0.5 mm or more;

[0047] (3) the adhesive layer has a width of 100 mm or less;

[0048] (4) the first metal foil and the second metal foil each have a
thickness of 5 to 70 .mu.m;

[0049] (5) the adhesive layer is provided either continuously or
discontinuously along the longitudinal direction of the first and the
second metal foil;

[0050] (6) the roll laminate satisfies the formula
0.ltoreq.d.ltoreq.0.1.times.r, where d is the maximum depth of a gap
created between the outermost surface of the roll laminate in the
thickness direction of the first and the second metal foil, and a
straight line drawn to connect the apices of bumps present on the
outermost surface of the roll laminate in positions corresponding to the
adhesive layers at both edge portions in the width of the first and the
second metal foil, and r is the roll thickness of the roll laminate;

[0051] (7) the maximum depth (d) of the gap created between the straight
line and the outermost surface of the roll laminate, and the roll
thickness (r) of the roll laminate as defined in (6) satisfy the formula
0.ltoreq.d.ltoreq.0.05.times.r;

[0052] (8) the adhesive constituting the adhesive layer has a viscosity of
3.times.10.sup.6 mPas (25.degree. C.) or less after 3 minutes from
application; and

[0053] (9) the adhesive constituting the adhesive layer has a viscosity of
1.times.10.sup.6 mPas (25.degree. C.) or less after 3 minutes from
application.

[0054] Yet another aspect of the present invention is a roll laminate
comprising a long first metal foil and a long second metal foil that are
bonded to each other via an adhesive layer, and are wound around a
support,

[0055] wherein the adhesive layer has a thickness of 1 .mu.m or more in at
least a part of the layer, and is provided along the longitudinal
direction of the first and the second metal foil in at least both edge
portions in the width of an overlapping region of the first and the
second metal foil viewed in plan, and

[0056] wherein:

[0057] the first metal foil is a carrier for a carrier-attached metal foil
that includes a carrier, an interlayer, and an ultrathin metal layer, in
this order, and

[0058] the second metal foil is an ultrathin metal layer for another
carrier-attached metal foil that includes a carrier, an interlayer, and
an ultrathin metal layer, in this order.

[0059] Still another aspect of the present invention is a roll laminate
comprising a long first metal foil and a long second metal foil that are
bonded to each other via an adhesive layer, and are wound around a
support,

[0060] wherein the adhesive layer has a thickness of 1 .mu.m or more in at
least a part of the layer, and is provided along the longitudinal
direction of the first and the second metal foil in at least both edge
portions in the width of an overlapping region of the first and the
second metal foil viewed in plan, and

[0061] wherein the first metal foil and the second metal foil each
comprise a carrier-attached metal foil that includes a carrier, an
interlayer, and an ultrathin metal layer, in this order.

[0062] In yet another embodiment of the roll laminate of the present
invention, the roll laminate satisfies at least one of the following (1)
to (10):

[0063] (1) the adhesive layer has a thickness of 300 jam or less;

[0064] (2) the adhesive layer has a width of 0.5 mm or more;

[0065] (3) the adhesive layer has a width of 100 mm or less;

[0066] (4) the first metal foil and the second metal foil each have a
thickness of 5 to 70 .mu.m;

[0067] (5) the adhesive layer is provided either continuously or
discontinuously along the longitudinal direction of the first and the
second metal foil;

[0068] (6) the roll laminate satisfies the formula
0.ltoreq.d.ltoreq.0.1.times.r, where d is the maximum depth of a gap
created between the outermost surface of the roll laminate in the
thickness direction of the first and the second metal foil, and a
straight line drawn to connect the apices of bumps present on the
outermost surface of the roll laminate in positions corresponding to the
adhesive layers at both edge portions in the width of the first and the
second metal foil, and r is the roll thickness of the roll laminate;

[0069] (7) the maximum depth (d) of the gap created between the straight
line and the outermost surface of the roll laminate, and the roll
thickness (r) of the roll laminate as defined in (6) satisfy the formula
0.ltoreq.d.ltoreq.0.05.times.r;

[0070] (8) the adhesive constituting the adhesive layer has a viscosity of
3.times.10.sup.6 mPas (25.degree. C.) or less after 3 minutes from
application;

[0071] (9) the adhesive constituting the adhesive layer has a viscosity of
1.times.10.sup.6 mPas (25.degree. C.) or less after 3 minutes from
application; and

[0072] (10)

[0073] (a) the first metal foil or the second metal foil protrudes beyond
the other at the both ends in the width of the roll laminate in a plan
view of the first and the second metal foil,

[0074] (b) one of the first metal foil and the second metal foil protrudes
beyond the other metal foil at one end of the roll laminate in the width
direction, and the other metal foil protrudes beyond the other at the
other end of the roll laminate in the width direction in a plan view of
the first and the second metal foil, or

[0075] (c) one of the first metal foil and the second metal foil protrudes
beyond the other metal foil at one end of the roll laminate in the width
direction, and the first and the second metal foil have aligned end
portions at the other end of the roll laminate in the width direction in
a plan view of the first and the second metal foil.

[0076] Still another aspect of the present invention is a method for
producing a roll laminate, the method comprising:

[0077] providing an adhesive layer along the longitudinal direction of a
long first metal foil in both edge portions in the width of the long
first metal foil;

[0078] bonding a long second metal foil to the adhesive layer-side surface
of the first metal foil provided with the adhesive layer; and

[0079] winding around a support the long first metal foil and the long
second metal foil that are bonded to each other via the adhesive layer.

[0080] Yet another aspect of the present invention is a method for
producing a roll laminate,

[0081] the method comprising:

[0082] providing an adhesive layer along the longitudinal direction of a
long first metal foil at both edge portions in the width of the first
metal foil, wherein the first metal foil is not a metal foil that
includes solely an insulating layer and a copper foil in this order on
the surface opposite the surface provided with the adhesive layer;

[0083] bonding a long second metal foil to the adhesive layer-side surface
of the first metal foil provided with the adhesive layer, wherein the
second metal foil is not a metal foil that includes solely an insulating
layer and a copper foil in this order on the surface opposite the surface
bonded to the first metal foil; and

[0084] winding around a support the long first metal foil and the long
second metal foil that are bonded to each other via the adhesive layer.

[0085] Still another aspect of the present invention is a method for
producing a roll laminate,

[0086] the method comprising:

[0087] taking the first and the second metal foil from (i) a roll laminate
comprising a long first metal foil and a long second metal foil that are
bonded to each other via an adhesive layer, and are wound around a
support, wherein the adhesive layer has a thickness of 1 .mu.m or more in
at least a part of the layer, and is provided along the longitudinal
direction of the first and the second metal foil in at least both edge
portions in the width of an overlapping region of the first and the
second metal foil viewed in plan, or (ii) a roll laminate produced by the
method of the present invention;

[0088] laminating a resin on at least one of the first metal foil and the
second metal foil; and

[0089] winding the first metal foil, the second metal foil, and the resin
around a support.

[0090] In an embodiment of the roll laminate producing method of the
present invention, the build-up substrate producing method of the present
invention, or the printed wiring board producing method of the present
invention, the roll laminate satisfies at least one of the following (1)
to (12):

[0091] (1) the adhesive layer has a thickness of 300 .mu.m or less;

[0092] (2) the adhesive layer has a width of 0.5 mm or more;

[0093] (3) the adhesive layer has a width of 100 mm or less;

[0094] (4) the first metal foil and the second metal foil each have a
thickness of 5 to 70 .mu.m;

[0095] (5) the adhesive layer is provided either continuously or
discontinuously along the longitudinal direction of the first and the
second metal foil;

[0096] (6) the roll laminate satisfies the formula
0.ltoreq.d.ltoreq.0.1.times.r, where d is the maximum depth of a gap
created between the outermost surface of the roll laminate in the
thickness direction of the first and the second metal foil, and a
straight line drawn to connect the apices of bumps present on the
outermost surface of the roll laminate in positions corresponding to the
adhesive layers at both edge portions in the width of the first and the
second metal foil, and r is the roll thickness of the roll laminate;

[0097] (7) the maximum depth (d) of the gap created between the straight
line and the outermost surface of the roll laminate, and the roll
thickness (r) of the roll laminate as defined in (6) satisfy the formula
0.ltoreq.d.ltoreq.0.05.times.r;

[0098] (8) the adhesive constituting the adhesive layer has a viscosity of
3.times.10.sup.6 mPas (25.degree. C.) or less after 3 minutes from
application;

[0099] (9) the adhesive constituting the adhesive layer has a viscosity of
1.times.10.sup.6 mPas (25.degree. C.) or less after 3 minutes from
application;

[0100] (10)

[0101] (a) the first metal foil or the second metal foil protrudes beyond
the other at the both ends in the width of the roll laminate in a plan
view of the first and the second metal foil,

[0102] (b) one of the first metal foil and the second metal foil protrudes
beyond the other metal foil at one end of the roll laminate in the width
direction, and the other metal foil protrudes beyond the other at the
other end of the roll laminate in the width direction in a plan view of
the first and the second metal foil, or

[0103] (c) one of the first metal foil and the second metal foil protrudes
beyond the other metal foil at one end of the roll laminate in the width
direction, and the first and the second metal foil have aligned end
portions at the other end of the roll laminate in the width direction in
a plan view of the first and the second metal foil;

[0104] (11) the first metal foil is a carrier for a carrier-attached metal
foil that includes a carrier, an interlayer, and an ultrathin metal
layer, in this order, and the second metal foil is the ultrathin metal
layer; and

[0105] (12) the first metal foil and the second metal foil each comprise a
carrier-attached metal foil that includes a carrier, an interlayer, and
an ultrathin metal layer, in this order.

[0106] Yet another aspect of the present invention is a method for
producing a laminate, the method comprising taking the first and the
second metal foil from the roll laminate of the present invention, or
from a roll laminate produced by the method of the present invention to
produce a laminate that includes the first and the second metal foil.

[0107] Still another aspect of the present invention is a method for
producing a build-up substrate,

[0108] the method comprising:

[0109] forming one or more build-up wiring layers on at least one surface
of a laminate produced by a method for producing a laminate that includes
a first and a second metal foil, or on at least one surface of a laminate
produced by the method of the present invention by taking the first and
the second metal foil from (i) a roll laminate comprising a long first
metal foil and a long second metal foil that are bonded to each other via
an adhesive layer, and are wound around a support, wherein the adhesive
layer has a thickness of 1 .mu.m or more in at least a part of the layer,
and is provided along the longitudinal direction of the first and the
second metal foil in at least both edge portions in the width of an
overlapping region of the first and the second metal foil viewed in plan,
or (ii) a roll laminate produced by the method of the present invention.

[0110] In another embodiment of the build-up substrate producing method of
the present invention, the build-up wiring layers are formed by using at
least one of a subtractive method, a full-additive method, and a
semi-additive method.

[0111] Yet another aspect of the present invention is a method for
producing a build-up substrate,

[0112] the method comprising:

[0113] laminating at least once a resin, a one-sided or double-sided
wiring board, a one-sided or double-sided metal clad laminate, a laminate
A, a laminate produced by the method of the present invention, a resin
substrate-attached metal layer, a carrier-attached metal layer, a wire, a
circuit, or a metal layer on at least one surface of a laminate A
produced by a method for producing a laminate A that includes a first and
a second metal foil, or on at least one surface of a laminate produced by
the method of the present invention by taking the first and the second
metal foil from (i) a roll laminate comprising a long first metal foil
and along second metal foil that are bonded to each other via an adhesive
layer, and are wound around a support, wherein the adhesive layer has a
thickness of 1 .mu.m or more in at least a part of the layer, and is
provided along the longitudinal direction of the first and the second
metal foil in at least both edge portions in the width of an overlapping
region of the first and the second metal foil viewed in plan, or (ii) a
roll laminate produced by the method of the present invention.

[0114] In still another aspect of the present invention, the build-up
substrate producing method of the present invention further comprises:

[0115] boring the resin, the one-sided or double-sided wiring board, the
one-sided or double-sided metal clad laminate, the laminate A, a laminate
produced by the method of the present invention, the resin
substrate-attached metal layer, the carrier-attached metal layer, the
wire, the circuit, or the metal layer; and

[0116] subjecting a side surface and a bottom surface of the bore to
conductive plating.

[0117] In yet another aspect of the present invention, the build-up
substrate producing method of the present invention further comprises:

[0118] forming a wire at least once on at least one of a metal layer
constituting the one-sided or double-sided wiring board, a metal layer
constituting the one-sided or double-sided metal clad laminate, a metal
foil constituting the laminate A, a metal foil constituting a laminate
produced by the method of the present invention, a metal layer
constituting the carrier-attached metal layer, a metal layer constituting
the resin substrate-attached metal layer, and the metal layer.

[0119] In an embodiment of the build-up substrate producing method of the
present invention, the method further comprises:

[0120] laminating, on a wire formed surface, a laminate produced by a
method for producing a laminate that includes the first and the second
metal foil, or a laminate produced by the method of the present invention
by taking the first and the second metal foil from (i) a roll laminate
comprising a long first metal foil and a long second metal foil that are
bonded to each other via an adhesive layer, and are wound around a
support, wherein the adhesive layer has a thickness of 1 .mu.m or more in
at least a part of the layer, and is provided along the longitudinal
direction of the first and the second metal foil in at least both edge
portions in the width of an overlapping region of the first and the
second metal foil viewed in plan, or (ii) a roll laminate produced by the
roll laminate producing method of the present invention.

[0121] In still another aspect of the present invention, the build-up
substrate producing method of the present invention further comprises
cutting the laminate A or a laminate produced by the method of the
present invention at at least one laminated surface of the metal foils
viewed in plan.

[0122] In yet another aspect of the present invention, the build-up
substrate producing method of the present invention further comprises
detaching and separating the metal foils of the cut laminate from each
other.

[0123] In still another aspect of the present invention, the build-up
substrate producing method of the present invention further comprises
removing the detached and separated metal foil either in part or as a
whole by etching.

[0124] Yet another aspect of the present invention is a method for
producing a printed wiring board, wherein the method uses a laminate
produced by a method for producing a laminate that includes the first and
the second metal foil, a laminate produced by the method of the present
invention, or a build-up substrate produced by the method of the present
invention by taking the first and the second metal foil from the roll
laminate of the present invention, or from a roll laminate produced by
the method of the present invention.

[0125] Still another aspect of the present invention is a method for
producing an electronic device using a printed wiring board produced by
the method of the present invention.

Advantageous Effects of Invention

[0126] The present invention can provide a roll laminate that can
desirably reduce scrapes on a metal foil surface even when a long metal
foil is wound into a roll, and that can improve the productivity in use
of the unwound roll metal foil.

BRIEF DESCRIPTION OF DRAWINGS

[0127] FIG. 1 is a cross sectional view showing a structure of a roll
laminate in an embodiment of the present invention.

[0129] FIGS. 3A and 3B are cross sectional views of laminates of a first
and a second metal foil obtained after unwinding and cutting a roll
laminate according to another embodiment of the present invention.

[0130] FIGS. 4A-4F are cross sectional views and plan views of laminates
of a first and a second metal foil obtained after unwinding and cutting a
roll laminate according to another embodiment of the present invention.

[0131] FIGS. 5A and 5B are schematic views showing cross sections of the
first and the second metal foil, explaining how the thickness of the
adhesive layer is measured in the present invention.

[0132] FIG. 6 is a schematic view showing an outline of a cross section of
the roll laminate.

DESCRIPTION OF EMBODIMENTS

[0133] Roll laminate

[0134] FIG. 1 is a cross sectional view showing a structure of a roll
laminate of the present invention. FIG. 2 shows a schematic view
describing a method for producing the roll laminate of the present
invention. The roll laminate of the present invention includes a long
first metal foil and a long second metal foil that are bonded to each
other via an adhesive layer, and are wound around a support. In the
present invention, the second metal foil of the roll laminate may be read
as a first metal foil, and the first metal foil of the roll laminate may
be read as a second metal foil.

[0135] The support may have a columnar or a tubular form. For example, the
support may have a form of a column or a cylinder, and may be made of a
material such as metal, resin, and paper. For cost and ease of handling,
the support may be, for example, a spool (paper core).

[0136] In an embodiment of the roll laminate producing method of the
present invention, as shown in FIG. 2, an adhesive layer may be provided
along the longitudinal direction (MD: machine direction) of the long
first metal foil in both edge portions in the width of the first metal
foil, using an adhesive dispenser, and the long second metal foil is
bonded to the surface on the adhesive layer side of the first metal foil
provided with the adhesive layer. After being bonded to each other via
the adhesive layer, the long first metal foil and the long second metal
foil can be wound around the support to obtain the roll laminate. As
illustrated in the cross sectional block diagram of FIG. 1, the roll
laminate produced in this manner is a long laminate of a two-layer
structure of the long first and second metal foils that are bonded to
each other via an adhesive layer, and the laminate is wound around the
support. The long laminate of the two-layer structure is wound multiple
times to constitute the roll laminate. The adhesive layer may be provided
in portions other than both edge portions in the width of the first metal
foil.

[0137] The adhesive layer may be provided either continuously or
discontinuously along the longitudinal direction of the first and the
second metal foil. As shown in FIG. 2, the adhesive layer is provided
along the longitudinal direction of the first and the second metal foil.
As shown in FIG. 3A, an additional adhesive layer may be provided between
the adhesive layers provided at the both edge portions in the width of
the first and second metal foils. As shown in FIG. 3B, a plurality of
additional adhesive layers maybe provided between the adhesive layers
provided at the both edge portions in the width of the first and second
metal foils. The adhesive layers provided between the first and second
metal foils may have the same or different widths. For example, the lower
limit of the adhesive layer width is preferably 0.5 mm or more,
preferably 1 mm or more, preferably 1.5 mm or more, preferably 2 mm or
more, preferably 2.5 mm or more, preferably 3 mm or more, though it is
not particularly limited. When the adhesive layer has a width of 0.5 mm
or more, the first metal foil and the second metal foil can be
sufficiently bonded to each other, and accidental detachment of the first
metal foil and the second metal foil becomes less likely to occur in
production of a printed wiring board. The upper limit of the adhesive
layer width is, for example, preferably 100 mm or less, preferably 95 mm
or less, preferably 90 mm or less, preferably 50 mm or less, preferably
30 mm or less, preferably 20 mm or less, preferably 10 mm or less, though
it is not particularly limited. Preferably, the width of the adhesive
layer is 100 mm or less because it requires less adhesive, and allows
wider areas of the first metal foil and the second metal foil to be used
in applications such as in a printed wiring board.

[0138] The adhesive layer has a thickness of 1 .mu.m or more in at least a
part of the layer, and is provided along the longitudinal direction of
the first and the second metal foil in at least both edge portions in the
width of an overlapping region of the first and the second metal foil of
the roll laminate viewed in plan. As used herein, "both edge portions"
refers to regions within 20% from each end of a planar overlapping region
of the first and the second metal foil in the width direction of the
first and the second metal foil. Examples of "the planar overlapping
region of the first and the second metal foil" are shown in the schematic
plan views of FIGS. 4B, 4D and 4F.

[0139] The width of the planar overlapping region of the first and the
second metal foil of the roll laminate is not particularly limited. It
is, however, preferable that the width of the planar overlapping region
be at least 50%, at least 60%, at least 70%, at least 80%, at least 90%,
or at least 95% of the same width of the first and the second metal foil,
or of the width of the narrower of the first and the second metal foil.
Preferably, the width of the overlapping region of the first and the
second metal foil is at least 50% of the same width of the first and the
second metal foil, or at least 50% of the width of the narrower of the
first and the second metal foil because it further prevents scrapes on
the first and the second metal foil.

[0140] As described above, the adhesive layer has a thickness of 1 .mu.m
or more in at least a part of the layer, and is provided along the
longitudinal direction of the first and the second metal foil in at least
both edge portions in the width of an overlapping region of the first and
the second metal foil viewed in plan. In this way, the first and the
second metal foil are less likely to rub against each other when
producing the roll laminate, or when using the roll laminate to produce a
laminate or a printed wiring board. The metal foils are accordingly less
likely to have scrapes on the laminated surface. The planar overlapping
region of the first and the second metal foil may be rectangular in
shape. Preferably, the adhesive layer has a thickness of 1 .mu.m or more
in at least one of an outer portion, a middle portion, and an inner
portion of the roll laminate. Preferably, the adhesive layer has a
thickness of 1 .mu.m or more in at least two, more preferably all of an
outer portion, a middle portion, and an inner portion of the roll
laminate. Preferably, the adhesive layer has a thickness of 1 .mu.m or
more over the entire length. When the adhesive layer has a thickness of 1
.mu.m or more in all of an outer portion, a middle portion, and an inner
portion, the adhesive layer can be regarded as having a thickness of 1
.mu.m or more over the entire length of the roll laminate. Because
removal of interleaving paper or the like is not needed when taking the
metal foils from the roll laminate for processing, the first and the
second metal foil can be processed in the laminated state. This improves
productivity. Further, the tension applied to the metal foil surfaces
becomes considerably small in regions where the adhesive layers are not
provided. Specifically, when the metal foils are electrolytic copper
foils, the roll laminate can be prevented from a loss of S (shiny)
surface smoothness due to transfer of the coarse shape of the M (matte)
surface to the S surface, or a loss of anchoring effect due to nodules
exfoliating from the M surface upon contact between the M surface and the
S surface of the copper foils. The roll laminate also can be prevented
from scrapes (abrasions) occurring when the copper foils rub or slide
(telescoping) against each other in the roll during transport such as by
a truck. It is also possible to prevent wrinkles on the metal foils
caused by the difference between inner and outer perimeters. The roll
laminate can be used as a copper foil laminate for printed circuit
boards. With the foregoing configuration, the laminate can have improved
strength, and deformation of the metal foils can be prevented while
improving ease of handling. It is also possible to desirably reduce
adhesion of contaminants such as a resin powder to metal foil surfaces.
These contribute to overall improvement of the productivity and the yield
of a printed board. When the thickness of the adhesive layer is less than
1 .mu.m throughout the roll laminate, the first metal foil and the second
metal foil may rub against each other, and cause scrapes.

[0141] The first metal foil and the second metal foil constituting the
roll laminate may have forms other than having the same size in width
direction as shown in FIG. 1 to FIGS. 3A and 3B. FIGS. 4A-4F illustrate
specific examples of such forms. FIG. 4A shows a schematic cross
sectional view of the first and the second metal foil constituting the
roll laminate, and FIG. 4B shows a plan view of the first and the second
metal foil. In FIGS. 4A and 4B, one of the first metal foil and the
second metal foil protrudes beyond the other metal foil at one end of the
roll laminate, and the other metal foil protrudes beyond the other at the
other end of the roll laminate in the width direction in a plan view of
the first and the second metal foil.

[0142] FIG. 4C shows a cross sectional schematic view of the first and the
second metal foil constituting the roll laminate, and FIG. 4D shows a
plan view of the first and the second metal foil. In FIGS. 4C and 4D, one
of the first metal foil and the second metal foil protrudes beyond the
other metal foil at one end of the roll laminate in the width direction,
and both of the first and the second metal foil have aligned end portions
at the other end of the roll laminate in the width direction in a plan
view of the first and the second metal foil.

[0143] FIG. 4E shows a cross sectional schematic view of the first and the
second metal foil constituting the roll laminate, and FIG. 4F shows a
plan view of the first and the second metal foil. In FIGS. 4E and 4F, one
of the first metal foil and the second metal foil protrudes beyond the
other metal foil at the both ends of the roll laminate in the width
direction in a plan view of the first and the second metal foil.

[0144] With regard to the size in the width direction of the first and the
second metal foil constituting the roll laminate, the first metal foil
and the second metal foil can be easily distinguished from each other by
making at least one of the metal foils protrude beyond the other. The
protrusion also makes it easier to peel the first metal foil or the
second metal foil from the other because it allows the protruding metal
foil to be held and peeled when the first metal foil and the second metal
foil need to be separated. This makes the procedure more efficient. The
protrusion also allows for printing or writing of a lot number or other
information, and makes it easier to distinguish among different roll
laminates, or among laminates obtained after unwinding and cutting the
roll laminate. This makes the procedure more efficient. The protrusion of
one of the metal foils also serves to protect the corners of the other
metal foil, and prevents bending or deformation of the metal foil during
transport or handling.

[0145] The minimum length by which the first metal foil or the second
metal foil protrudes from the other metal foil is not particularly
limited. For example, the protrusion length is preferably 0.5% or more,
preferably 1% or more, preferably 2% or more, preferably 5% or more of
the same width of the first metal foil and the second metal foil, or of
the width of the wider of the first metal foil and the second metal foil.
The foregoing effects become more pronounced when the protrusion length
is 0.5% or more of the same width of the first metal foil and the second
metal foil, or of the width of the wider of the first metal foil and the
second metal foil.

[0146] The maximum length by which the first metal foil or the second
metal foil protrudes from the other metal foil is not particularly
limited. For example, the protrusion length is preferably 40% or less,
preferably 35% or less, preferably 30% or less, preferably 25% or less,
preferably 20% or less, preferably 15% or less of the same width of the
first metal foil and the second metal foil, or of the width of the wider
of the first metal foil and the second metal foil. The first metal foil
and the second metal foil become less likely to be scraped when the
protrusion length is 40% or less of the same width of the first metal
foil and the second metal foil, or of the width of the wider of the first
metal foil and the second metal foil.

[0147] The thickness of the adhesive layer is preferably 2 .mu.m or more,
more preferably 3 .mu.m or more, further preferably 5 .mu.m or more. The
upper limit of the adhesive layer thickness is preferably 500 .mu.m or
less, preferably 400 .mu.m or less, preferably 300 .mu.m or less,
preferably 200 .mu.m or less, preferably 100 .mu.m or less, preferably 50
.mu.m or less, though it is not particularly limited. Smaller thicknesses
are preferred because thinner adhesive layers use less amounts of
adhesive, and can reduce the manufacturing cost.

[0148] In the present invention, the thickness of the adhesive layer is
measured as follows.

[0149] FIG. 5A shows a cross sectional view of the first and the second
metal foil after unwinding and cutting the roll laminate into a laminate
of the first and the second metal foil. In the cross sectional view, the
thickness of the adhesive layer (adhesive layer J as the example shown in
FIG. 5B) is measured as the mean value of the distance of a straight line
extending along the thickness of the metal foil and connecting point A,
where an edge of the adhesive layer J meets one of the metal foils, and
point B, where the straight line crosses the other metal foil, as shown
in FIG. 5B. The edges of the adhesive layer J on the metal foils are at
points A1 to A4. B1 to B4 are points where the straight lines extending
from points A1 to A4 along the thickness direction of the metal foil
reach the other metal foil, respectively. When the distances from A1 to
B1, A2 to B2, A3 to B3, and A4 to B4 are t1, t2, t3, and t4,
respectively, the thickness of the adhesive layer J is given as the
arithmetic mean value of tl to t4.

[0150] Thickness t of adhesive layer J=(t1+t2+t3+t4)/4

[0151] When more than one adhesive layer is present in a cross section of
the laminate of the first and the second metal foil, the adhesive layer
thickness is given as the arithmetic mean value of the thicknesses of the
adhesive layers calculated by the method described above. As a specific
example, when two adhesive layers are present in a cross section of the
laminate of the first and the second metal foil, the adhesive layer
thickness is the arithmetic mean value of the thicknesses of the two
adhesive layers.

[0152] In the present invention, the width of the adhesive layer is
measured as follows.

[0153] In FIG. 5B, the distance from A1 to A4 is w1. The distance from A2
to A3 is w2. The width of the adhesive layer J is the arithmetic mean
value of width w1 and width w2.

[0154] Width w of adhesive layer J=(w1+w2)/2

[0155] When more than one adhesive layer is present in a cross section of
the laminate of the first and the second metal foil, the adhesive layer
width is given as the arithmetic mean value of the widths of the adhesive
layers calculated by the method described above. As a specific example,
when two adhesive layers are present in a cross section of the laminate
of the first and the second metal foil, the adhesive layer width is the
arithmetic mean value of the widths of the two adhesive layers.

[0156] When the metal foils to be bonded to each other are cut sheets, the
metal foils need to be pressed down with a roller to remove air between
the cut sheets and within the laminate, and the adhesive is cured to bond
the metal foils. In contrast, when the first metal foil and the second
metal foil are bonded to each other via the adhesive layer to produce the
roll laminate as in the present invention, air is discharged while
rolling and winding the metal foils, and no extra step is needed to
remove air.

[0157] The first metal foil and the second metal foil may be taken from
the roll laminate, and one of the metal foils may be bonded to a prepreg
sheet such as a glass fiber-reinforced epoxy resin to produce a prepreg
sheet-attached laminate, and use it for lamination to a printed circuit
board. Such a configuration improves the laminate strength, and prevents
deformation of the metal foil. It also becomes easier to handle the metal
foil, and adhesion of contaminants such as a resin powder to the metal
foil surface can be desirably reduced.

[0158] In the roll laminate of the present invention, the laminate wound
around the support is a two-layer which has laminated structure of the
first and the second metal foil with the adhesive layer provided in both
edge portions in the width of the first and the second metal foils. In
this case, as schematically outlined view in the cross section shown in
FIG. 6, bumps may occur on the outermost surface of the roll laminate in
the thickness direction of the first and the second metal foil in
positions corresponding to the adhesive layers provided in both edge
portions in the width of the first and the second metal foil. Here, when
a straight line drawn to connect the apices of the bumps is L, it is
preferable that the maximum depth (d) of the gap created between the
straight line L and the outermost surface of the roll laminate, and the
roll thickness (r) of the roll laminate satisfy the formula
0.ltoreq.d.ltoreq.0.1.times.r.

[0159] The gap will be sufficiently small when the maximum depth (d) of
the gap created between the straight line L and the outermost surface of
the roll laminate is within 10% of the roll thickness (r) of the roll
laminate, and contact between the first and the second metal foil due to
bending of the first and the second metal foil in the roll laminate can
be desirably reduced.

[0160] More preferably, the maximum depth (d) of the gap created between
the straight line L and the outermost surface of the roll laminate, and
the roll thickness (r) of the roll laminate satisfy the formula
0.ltoreq.d.ltoreq.0.05.times.r, or, typically, 500 .mu.m
.ltoreq.d.ltoreq.0.1.times.r.

[0161] The roll thickness r is not particularly limited, but is typically
5 mm or more, 10 mm or more, 50 mm or more, 70 mm or more, or 100 mm or
more, and is typically 1,500 mm or less, 1,400 mm or less, 1,300 mm or
less, 1,000 mm or less, or 900 mm or less.

[0162] Preferably, the adhesive constituting the adhesive layer has a
viscosity of 3.times.10.sup.6 mPas (25.degree. C.) or less after 3
minutes from application. When the viscosity of the adhesive layer is
excessively high, the first metal foil and the second metal foil become
overly fixed, and wrinkles or cracks may occur as such excessively high
viscosity makes it difficult to accommodate an externally applied load.
When the viscosity of the adhesive constituting the adhesive layer is
3.times.10.sup.6 mPas (25.degree. C.) or less after 3 minutes from
application, an externally applied load can be accommodated even though
the first and the second metal foil are bonded, and wrinkles and cracks
can be reduced. Preferably, the viscosity of the adhesive constituting
the adhesive layer is 1.times.10.sup.6 mPas (25.degree. C.) or less after
3 minutes from application.

[0163] The adhesive constituting the adhesive layer may be, for example,
at least one of an epoxy-based adhesive, an acrylic-based adhesive, a
methacrylate-based adhesive, silicon rubber-based adhesive, a
ceramic-based adhesive, and a rubber-based adhesive.

[0164] The long first metal foil, and the long second metal foil are not
particularly limited, as long as these are metal foils. For example, the
first and the second metal foil may be any of a copper foil, an
electrolytic copper foil, a rolled copper foil, a copper alloy foil, a
nickel foil, a nickel alloy foil, an iron foil, an iron alloy foil, a
stainless steel foil, an aluminum foil, an aluminum alloy foil, a zinc
foil, and a zinc alloy foil.

[0165] Preferably, the long first metal foil and the long second metal
foil each have a thickness of 5 to 70 .mu.m, respectively. With such a
configuration, the first and the second metal foil do not bend as much as
the thickness, 1 to 50 .mu.m, of the adhesive layer (i.e., the gap
between the first metal foil and the second metal foil), and contact
between the first and the second metal foil can be desirably reduced.

[0166] It is not necessarily required to limit the width of the metal foil
used for the roll laminate. However, the metal foil has a width of
typically 100 mm or more, 200 mm or more, or 300 mm or more, and a width
of typically 3,000 mm or less, 2,500 mm or less, 2,000 mm or less, 1,800
mm or less, 1,600 mm or less, or 1,500 mm or less. As used herein, "metal
foil" may include the first metal foil, and the second metal foil.

[0167] The length of the metal foil used for the roll laminate is not
particularly limited either. However, the metal foil has a length of
typically 10 m or more, 20 m or more, or 30 m or more, and a length of
typically 50,000 m or less, 40,000 m or less, 30,000 m or less, 20,000 m
or less, or 18,000 m or less.

[0168] The roll laminate of the present invention may be a roll laminate
that does not fall into the following categories (A) to (C) of the roll
laminate.

[0169] (A) A roll laminate consisting of a structure in which:

[0170] only a first insulating layer and a first copper foil layer are
provided in such order that the roll laminate has the first insulating
layer on the surface of the first metal foil opposite the surface that is
in contact with the second metal foil, and the first copper foil layer on
the surface of the first insulating layer opposite the first metal foil,
and

[0171] only a second insulating layer and a second copper foil layer are
provided in such order that the roll laminate has the second insulating
layer on the surface of the second metal foil opposite the surface that
is in contact with the first metal foil, and the second copper foil layer
on the surface of the second insulating layer opposite the surface that
is in contact with the second metal foil.

[0172] (B) A roll laminate consisting of a structure in which:

[0173] only a first insulating layer, a first copper foil layer, and a via
hole are provided, wherein the first insulating layer is provided on the
surface of the first metal foil opposite the surface that is in contact
with the second metal foil, the first copper foil layer is provided on
the surface of the first insulating layer opposite the surface that is in
contact with the first metal foil, and the via hole is provided through
the first insulating layer and the first copper foil layer, and

[0174] only a second insulating layer, a second copper foil layer, and a
via hole are provided, wherein the second insulating layer is provided on
the surface of the second metal foil opposite the surface that is in
contact with the first metal foil, the second copper foil layer is
provided on the surface of the second insulating layer opposite the
surface that is in contact with the second metal foil, and the via hole
is provided through the second insulating layer and the second copper
foil layer.

[0175] (C) A roll laminate consisting of a structure in which:

[0176] only a first insulating layer, a first copper foil layer, a first
metal layer, and a first via hole are provided, wherein the first
insulating layer is provided on the surface of the first metal foil
opposite the surface that is in contact with the second metal foil, the
first copper foil layer is provided on the surface of the first
insulating layer opposite the surface that is in contact with the first
metal foil, the first via hole is provided through the first insulating
layer and the first copper foil layer, and the first metal layer is
provided on the surface of the first copper foil layer opposite the
surface that is in contact with the first insulating layer, and in the
first via hole, and

[0177] only a second insulating layer, a second copper foil layer, a
second metal layer, and a second via hole are provided, wherein the
second insulating layer is provided on the surface of the second metal
foil opposite the surface that is in contact with the first metal foil,
the second copper foil layer is provided on the surface of the second
insulating layer opposite the surface that is in contact with the second
metal foil, the second via hole is provided through the second insulating
layer and the second copper foil layer, and the second metal layer is
provided on the surface of the second copper foil layer opposite the
surface that is in contact with the second insulating layer, and in the
second via hole.

Carrier-Attached Metal Foil

[0178] The roll laminate of the present invention may be a roll laminate
in which the first metal foil and the second metal foil are
carrier-attached metal foils each having a carrier, an interlayer, and an
ultrathin metal layer, in this order. In this case, the roll laminate may
be produced by bonding the carrier-side surface of the first metal foil
(first carrier-attached metal foil) to the carrier-side surface of the
second metal foil (second carrier-attached metal foil) via the adhesive
layer. Here, a coreless substrate can be produced by using a laminate in
which the first and the second carrier-attached metal foil are bonded to
each other on the carrier side via the adhesive layer. The laminate may
be one obtained by cutting the laminate having the first metal foil and
the second metal foil after taking them from the roll laminate.
Preferably, the ultrathin metal layer may be an ultrathin copper layer.
As used herein, "carrier-attached metal foil" may include
carrier-attached copper foil. In the specification, the carrier-attached
metal foil may be read as carrier-attached copper foil.

[0179] The roll laminate also can be produced by bonding the carrier-side
surface of the first metal foil (first carrier-attached metal foil) or
the second metal foil (second carrier-attached metal foil) to the
ultrathin metal layer-side surface of the other metal foil via the
adhesive layer.

[0180] The roll laminate also may be one produced by bonding the ultrathin
metal layer-side surface of the first metal foil (first carrier-attached
metal foil) or the second metal foil (second carrier-attached metal foil)
to the ultrathin metal layer-side surface of the other metal foil via the
adhesive layer. The first and the second carrier-attached metal foil may
be known carrier-attached metal foils.

[0181] The manufacturing process of the roll metal foil of the
carrier-attached metal foil for printed circuit boards is described
below. The carrier-attached metal foil is typically configured to include
the ultrathin metal layer formed by being bonded to the whole surface of
the carrier via a release layer so that the ultrathin metal layer can be
easily peeled off. Specifically, when the ultrathin metal layer is
configured as an electrolytic metal foil, the matte surface is formed on
the side that faces the carrier. During manufacture, a carrier-attached
metal foil with the metal layer bonded to the whole surface of the
carrier is wound around, for example, a paper core with the matte surface
of the ultrathin metal layer contacting the carrier. Here, the matte
surface of the ultrathin metal layer often experiences damage caused by
contact with the carrier. For example, because the carrier and the
ultrathin metal layer rub against each other, nodules (particles
generated from roughening) often exfoliate from the roughened layer
formed on the matte surface of the ultrathin metal layer. Abrasions
(scratches) due to vibration may also occur during transport of the roll
metal foil (copper foil). In contrast, the carrier and the ultrathin
metal layer are less likely to be damaged by the configuration of the
present invention described above because the carrier-attached metal
foils are wound around the support after bonding the carriers via the
adhesive layer, or after bonding the carrier of either carrier-attached
metal foil to the ultrathin metal layer of the other. A laminate with the
two-layer bonded structure of the carrier and the ultrathin metal layer
typically experiences a tension of 100 to 1,000 N/m when being wound
around a support. Because the load of the tension concentrates on the
adhesive layer, the foregoing configuration desirably reduces abrasions
(scratches) between the carrier and the ultrathin metal layer, and
exfoliation of nodules from the matte surface.

[0182] Removal of interleaving paper or the like is also not necessary for
processing of the metal foil (carrier-attached metal foil) taken from the
roll laminate, and the first and the second metal foil (the first and the
second carrier-attached metal foil) can be processed directly in the
laminated state. This improves productivity. Further, because the first
and the second metal foil being would into a roll are less likely to
experience tension in portions where the adhesive layer is not provided,
the matte surfaces of the first and the second metal foil (matte surfaces
of the ultrathin metal layers of the first and the second
carrier-attached metal foil) are less likely to rub against and contact
each other in these portions, making it possible to desirably reduce the
foreign object metal powder that occurs at the laminated surface from the
matte surface. It is also possible to improve the ease of handling when
rolling out the first and the second metal foil for use (when taking the
metal foils from the roll laminate for use).

[0183] As used herein, "carrier-attached metal foil" may include a
carrier-attached copper foil. As used herein, "ultrathin metal layer" may
include an ultrathin copper layer. As used herein, "electrolytic metal
foil" may include an electrolytic copper foil. As used herein, "roll
metal foil" may include a roll copper foil.

[0184] The carrier-attached metal foils obtained from the roll laminate
may be used to produce a printed wiring board, as follows. For example,
the ultrathin metal layer surface or the carrier surface is attached to
an insulating substrate such as a paper base phenolic resin, a paper base
epoxy resin, a synthetic fiber fabric base epoxy resin, a glass
fabric-paper composite base epoxy resin, a glass fabric-glass nonwoven
fabric composite base epoxy resin, a glass fabric base epoxy resin, a
polyester film, and a polyimide film. After thermocompression, the
ultrathin metal layer or the carrier is peeled off, and etched to form
the desired conductor pattern to produce a printed wiring board.

[0185] As an example of use of the roll laminate, the roll laminate
provided to the manufacturing process may be cut into a sheet of the
desired length, and the resulting laminate of the first and the second
metal foil (hereinafter, also referred to as "sheet metal foil laminate")
may be stacked to make a repeat of a configuration constructed from the
sheet metal foil laminate, a prepreg, the sheet metal foil laminate, and
an SUS middle plate, and followed by hot press. As another example, a
metal foil laminate rolled out of the roll laminate may be used to make a
configuration constructed from the metal foil laminate, a prepreg, and
the metal foil laminate, and laminated with a hot-press roll
(roll-to-roll method) to produce, for example, a metal (copper) clad
laminate plate.

[0186] The first and the second metal foil may be taken from the roll
laminate of the present invention, and cut to produce a laminate having
the first and the second metal foil. A coreless build-up substrate can be
produced by forming one or more build-up wiring layers on at least one
surface of the laminate, or on at least one surface of a laminate having
a form in which the first and the second metal foil are contained by
being covered with a resin layer and the other metal foil.

[0187] The build-up wiring layer may be formed by using one or more of the
subtractive method, the full-additive method, and the semi-additive
method. A build-up substrate can be produced by laminating a resin, a
one-sided or double-sided wiring board, a one-sided or double-sided metal
clad laminate, a laminate produced by the method of the present
invention, a resin substrate-attached metal layer, a carrier-attached
metal layer, a wire, a circuit, or a metal layer at least once on at
least one surface of a laminate produced by the method of the present
invention. The resin, the one-sided or double-sided wiring board, the
one-sided or double-sided metal clad laminate, the laminate, the resin
substrate-attached metal layer, the carrier-attached metal layer, the
wire, the circuit, or the metal layer may be bored, and the side surface
and the bottom surface of the bore may be subjected to conductive
plating.

[0188] A build-up substrate may be produced by forming a wire at least
once on at least one of a metal layer constituting the one-sided or
double-sided wiring board, a metal layer constituting the one-sided or
double-sided metal clad laminate, a metal foil constituting the laminate,
a metal layer constituting the carrier-attached metal layer, a metal
layer constituting the resin substrate-attached metal layer, and the
metal layer. A laminate produced by the method of the present invention
may be further laminated on the wired surface to produce a build-up
substrate. A build-up substrate may be produced by cutting the laminate
at at least one laminated surface of the metal layers viewed in plan. The
metal layers in the cut laminate may be detached and separated from each
other to produce a build-up substrate. The detached and separated metal
layer may be removed either in part or as a whole by etching to produce a
build-up substrate.

[0189] A resin layer may be laminated on the both outer surfaces of the
laminate of the first and the second metal foil, and a metal foil may be
laminated on the resin layer. Here, the resin layer, and the overlying
metal foil maybe larger in size than the first and the second metal foil
so that the laminate has a form in which the resin layer and the
overlying metal foil cover and contain the first and the second metal
foil. The first and the second metal foil may be carrier-attached metal
foils. A known resin, and/or a known prepreg may be used for the resin
layer. The resin layer may be plate-shaped.

[0190] The laminate or the build-up substrate obtained by using the method
of the present invention may be used to produce a printed wiring board.
The printed wiring board becomes a complete printed circuit board upon
mounting electronic components. In the present invention, "printed wiring
board" encompasses printed wiring boards, printed circuit boards, and
printed boards having electronic components mounted thereon.

[0191] The printed wiring board may be used to produce an electronic
device. The printed circuit board with the mounted electronic components
may be used to produce an electronic device. The printed board with the
mounted electronic components may be used to produce an electronic
device.

EXAMPLES

[0192] The present invention is described below in greater detail by way
of Examples. It is to be noted that the present invention is in no way
limited by the following Examples.

[0193] As a rule, an adhesive cures after application, and its viscosity
constantly varies with time. To take this into consideration, the
viscosity of the adhesive used was measured in advance at 25.degree. C.
after 3 minutes from application, using a rotary viscometer (B-type
viscometer, a Brookfield rotary viscometer HA DV3T available from
Brookfield). The viscosity of the adhesives used in the Examples below
was adjusted by adjusting the degree of polymerization of the polymer
material contained in the adhesive.

Example 1

1. Production of Roll Laminate

[0194] The long first and the second metal foil were transported with the
transport rolls of the manufacturing apparatus prepared as shown in FIG.
2. An electrolytic copper foil measuring 12 .mu.m in thickness and 500 mm
in width was used as the first metal foil. For the second metal foil, an
18 .mu.m-thick, 500 mm-wide rolled copper foil was used.

[0195] Thereafter, an acrylic adhesive layer having a viscosity of
3.times.10.sup.6 mPas (25.degree. C.) or less after 3 minutes from
application was continuously applied along the longitudinal direction of
the first metal foil at both edge portions of the S surface in the width
of the long first metal foil.

[0196] The S surface of the long first metal foil was then bonded to the S
surface of the long second metal foil via the adhesive layer to form a
laminate of a two-layer structure, and the laminate was wound around a
support spool to produce the roll laminate as shown in FIGS. 1 and 6.

2. Evaluation of Roll Laminate

[0197] The adhesive layer had thicknesses of 8.5 .mu.m, 10 .mu.m, and 11.3
.mu.m at an outer portion, a middle portion, and an inner portion,
respectively, of the roll laminate. The adhesive layer had widths of
0.8-mm, 0.6-mm, and 0.5-mm at the outer portion, the middle portion, and
the inner portion, respectively, of the roll laminate. The thickness and
the width of the adhesive layer were measured in the manner described
below (the original roll thickness of the roll laminate is r1 [mm]).

Sampling

[0198] Outer portion: the first surface layer of the roll laminate was
peeled away, and the second layer of the laminate was cut into a sheet
form.

[0199] Middle portion: the roll laminate was unwound until the roll
thickness became r1.times.(1/2.+-.0.05), and the laminate was cut into a
sheet form.

[0200] Inner portion: the roll laminate was unwound until the roll
thickness became r1.times.0.1 to r1.times.0.05, and the laminate was cut
into a sheet form.

[0201] The outer, middle, and inner sheet-like shaped laminates were then
measured the thickness and the width of the adhesive layer at two
locations on the cut cross section of each laminate in the manner
described above, and the arithmetic mean values of the thicknesses and
the widths of the adhesive layer were determined for these two locations.

[0202] The first and the second metal foil did not have wrinkles or
cracks. The first and the second metal foil did not have scrapes on the
adhesive layer-side surfaces upon inspection of the first and the second
metal foil taken from the roll laminate, and detached from each other.

[0203] On the outermost surface of the roll laminate in the thickness
direction of the first and the second metal foil, a straight edge (Matsui
Measure MFG, Co., Ltd., flatness ruler, length 600 mm, single blade/no
indentation) was placed across the apices of bumps corresponding in
position to the adhesive layers formed at both edge portions in the width
of the first and the second metal foil. The maximum depth (d) of the gap
created between the straight edge and the outermost surface of the roll
laminate was 50 .mu.m, and the roll thickness (r) of the roll laminate
was 500 mm, satisfying the formula 0.ltoreq.d.ltoreq.0.1.times.r. Instead
of the straight edge, a plate or a ruler made of a rigid, undeformable
material, for example, metal, and organic material may be used for the
measurement. A feeler gauge may be used for the measurement of the
maximum depth d. Maximum depth d was measured at three circumferential
locations of the roll laminate, and the arithmetic mean value of the
three measured values of d was determined as the maximum depth d of the
roll laminate.

Example 2

1. Production of Roll Laminate

[0204] The long first and the second metal foil were transported with the
transport rolls of the manufacturing apparatus prepared as shown in FIG.
2. A carrier-attached copper foil (ultrathin copper layer thickness=5
.mu.m, carrier thickness=18 .mu.m, width=540 mm) was used as the first
metal foil. A carrier-attached copper foil (ultrathin copper layer
thickness=5 .mu.m, carrier thickness=18 .mu.m, width=540 mm) was used as
the second metal foil.

[0205] A silicon rubber-based adhesive layer having a viscosity of
3.times.10.sup.6 mPas (25.degree. C.) or less after 3 minutes from
application was continuously applied along the longitudinal direction of
the first metal foil at both edge portions of the carrier surface in the
width of the long first metal foil (the coated portion was 1 cm in
length, and the uncoated portion was 3 cm in length).

[0206] The long first metal foil, and the long second metal foil were then
bonded to each other on the carrier surfaces via the adhesive layer to
form a laminate of a two-layer structure, and the laminate was wound
around a support spool to produce the roll laminate as shown in FIGS. 1
and 6.

2. Evaluation of Roll Laminate

[0207] The adhesive layer had thicknesses of 6.8 .mu.m, 5.0 .mu.m, and 5.2
.mu.m at an outer portion, a middle portion, and an inner portion,
respectively, of the roll laminate. The adhesive layer had widths of
1.4-mm, 1.5-mm, and 1.5-mm at the outer portion, the middle portion, and
the inner portion, respectively, of the roll laminate. The first and the
second metal foil did not have wrinkles or cracks. The first and the
second metal foil did not have scrapes on the adhesive layer-side
surfaces and the ultrathin copper layer surfaces upon inspection of the
first and the second metal foil taken from the roll laminate, and
detached from each other.

[0208] On the outermost surface of the roll laminate in the thickness
direction of the first and the second metal foil, a straight line was
drawn across the apices of bumps corresponding in position to the
adhesive layers formed at both edge portions in the width of the first
and the second metal foil. The maximum depth (d) of the gap created
between the straight edge and the outermost surface of the roll laminate
was 30 .mu.m, and the roll thickness (r) of the roll laminate was 500 mm,
satisfying the formula 0.ltoreq.d.ltoreq.0.1.times.r.

Example 3

1. Production of Roll Laminate

[0209] The long first and the second metal foil were transported with the
transport rolls of the manufacturing apparatus prepared as shown in FIG.
2. A carrier-attached copper foil (ultrathin copper layer
thickness=5.mu.m, carrier thickness=18 .mu.m, width=500 mm) was used as
the first metal foil. An aluminum foil (thickness=40 .mu.m, width=510 mm)
was used as the second metal foil.

[0210] A methacrylate-based adhesive layer having a viscosity of
3.times.10.sup.6 mPas (25.degree. C.) or less after 3 minutes from
application was continuously applied along the longitudinal direction of
the first metal foil at both edge portions of the carrier surface in the
width of the long first metal foil.

[0211] The long first metal foil, and the long second metal foil were then
bonded to each other on the carrier surfaces via the adhesive layer to
form a laminate of a two-layer structure, and the laminate was wound
around a support spool to produce the roll laminate as shown in FIGS. 1
and 6. The laminate of a two-layer structure had a configuration in which
the aluminum foil (width=510 mm), or the second metal foil, protruded
beyond the carrier-attached copper foil (width=500 mm), or the first
metal foil, by 5 mm at each end in the width direction.

2. Evaluation of Roll Laminate

[0212] The adhesive layer had thicknesses of 2.1 .mu.m, 3.0 .mu.m, and 4.0
.mu.m at an outer portion, a middle portion, and an inner portion,
respectively, of the roll laminate. The adhesive layer had widths of
3.5-mm, 3.4-mm, and 3.4-mm at the outer portion, the middle portion, and
the inner portion, respectively, of the roll laminate. The first and the
second metal foil did not have wrinkles or cracks. The first and the
second metal foil did not have scrapes on the adhesive layer-side
surfaces and the ultrathin copper layer surfaces upon inspection of the
first and the second metal foil taken from the roll laminate, and
detached from each other.

[0213] On the outermost surface of the roll laminate in the thickness
direction of the first and the second metal foil, a straight line was
drawn across the apices of bumps corresponding in position to the
adhesive layers formed at both edge portions in the width of the first
and the second metal foil. The maximum depth (d) of the gap created
between the straight edge and the outermost surface of the roll laminate
was 10 .mu.m, and the roll thickness (r) of the roll laminate was 500 mm,
satisfying the formula 0.ltoreq.d.ltoreq.0.1.times.r.

Example 4

1. Production of Roll Laminate

[0214] The long first and the second metal foil were transported with the
transport rolls of the manufacturing apparatus prepared as shown in FIG.
2. An electrolytic copper foil measuring 12 .mu.m in thickness and 1,290
mm in width was used as the first metal foil. An electrolytic copper foil
measuring 12 .mu.m in thickness and 1,290 mm in width was used as the
second metal foil.

[0215] An acrylic adhesive layer having a viscosity of 3.times.10.sup.6
mPas (25.degree. C.) or less after 3 minutes from application was
continuously applied along the longitudinal direction of the first metal
foil at both edge portions of the S surface in the width of the long
first metal foil.

[0216] The S surface of the long first metal foil, and the S surface of
the long second metal foil were then bonded to each other via the
adhesive layer to form a laminate of a two-layer structure, and the
laminate was wound around a support spool to produce the roll laminate as
shown in FIGS. 1 and 6.

2. Evaluation of Roll Laminate

[0217] The adhesive layer had thicknesses of 15.9 .mu.m, 10.8 .mu.m, and
13.6 .mu.m at an outer portion, a middle portion, and an inner portion,
respectively, of the roll laminate. The adhesive layer had widths of
35.3-mm, 36.1-mm, and 35.8-mm at the outer portion, the middle portion,
and the inner portion, respectively, of the roll laminate. The first and
the second metal foil did not have wrinkles or cracks. The first and the
second metal foil did not have scrapes on the adhesive layer-side
surfaces upon inspection of the first and the second metal foil taken
from the roll laminate, and detached from each other.

[0218] On the outermost surface of the roll laminate in the thickness
direction of the first and the second metal foil, a straight line was
drawn across the apices of bumps corresponding in position to the
adhesive layers formed at both edge portions in the width of the first
and the second metal foil. The maximum depth (d) of the gap created
between the straight edge and the outermost surface of the roll laminate
was 50 .mu.m, and the roll thickness (r) of the roll laminate was 500 mm,
satisfying the formula 0.ltoreq.d.ltoreq.0.1.times.r.

[0219] This application claims priority from Japanese Patent Application
No. 2016-103755, filed on May 24, 2016, the entire disclosure of which is
incorporated herein by reference.